Thermomechanical Simulation of Continuous Extrusion

Thermomechanical Simulation of Continuous Extrusion

Xavier Velay, Bournemouth University, Bournemouth, UK

Track: EXTRUSION/DIE, THEORETICAL - Modeling and Simulation

ABSTRACT --- Three dimensional analyses using finite element modeling were
carried out to simulate continuous extrusion. The simulations highlighted best
practice for efficiently modeling continuous extrusion in 3D and included the
degree of mesh refinement, boundary conditions, and the modeling of different
tools. The influence of the flash in continuous extrusion was also studied
together with the formation of multiple dead-metal zones. These results were
then compared with experimental work. The influence of the coining roll on the
feedstock was also studied. This section of the paper studies the heat transfer
between the feedstock, the wheel, the coining roll, and the surrounding air during
the coining process until the point when the feedstock reaches the upset zone. A
methodology is derived from the results to evaluate the right balance between the
velocity of the wheel, the initial grip length, and the cooling of the wheel.